Design and Testing of a Unique Compressor Test Facility Jörgen Olsson STARCS Proprietary

Outline of the presentation Introduction Specifications Design Hardware Test Compressors Testing Summary STARCS Proprietary

What type of compressors are tested? Low Pressure Compressor RM 12 (GE F404) STARCS Proprietary

Why are compressors tested? Measure the performance of a new design Map the operational envelope Establish the operational limits to avoid stall, surge and flutter Verification of design models STARCS Proprietary

Main design criteria for the Compressor Research Facility Drive power 4.3 MW Rotation speed ranges: 0-5500 rpm and 0-25000 rpm, continuously variable Variable inlet pressure Variable outlet pressure Air flow through the test facility without a test compressor installed Efficient sound proofing of the control room and to the external environment. Control system with safety monitoring and logging STARCS Proprietary

Envelope of the Compressor Test Facility STARCS Proprietary

STAL-LAVAL (Siemens Turbomachinery Finspång Sweden) Compressor Test Facility In service fall 1973 6 MW STARCS Proprietary

First sketch STARCS Proprietary

Compressor Test Facility Overview STARCS Proprietary

Side view of the Compressor Test Facility Asynchronous motor 4.3 MW Inlet valve Test object (rig) Outlet valve (2) Counter weight Control valve for ejector primary flow STARCS Proprietary

The Compressor Test Facility seen from the motor Inlet valve Outlet valve Outlet valve To acoustic baffles and exhaust tower Floor level Ejector Control valve for ejector primary flow STARCS Proprietary

Inlet flow manipulators Perforated plate Net Net Net STARCS Proprietary

Cross section at the ejector STARCS Proprietary

Modified ejector Insert STARCS Proprietary

16 MPa pipe for the ejector drive air Compressor building for wind tunnel T1500 Connection to pressure vessel Compressor Research Facility Shut off valve Pipe Pipe support Control valve STARCS Proprietary

Gearboxes Sketch of the gear box for 25000 rpm Cut away sketch of the gearbox for 5500 rpm STARCS Proprietary

Drive shafts between gear box and test compressor STARCS Proprietary

Torque meters 0-10 kNm 0-8000 rpm 0-1400 Nm 0-30000 rpm STARCS Proprietary

Situation plan STARCS Proprietary

External view of the building STARCS Proprietary

Motor and 25000 rpm gear box STARCS Proprietary

Gear box and exhaust annular collector STARCS Proprietary

Air inlet with inlet valve and stagnation chamber STARCS Proprietary

Hardware needed to adapt a test compressor STARCS Proprietary

Inlet pipe STARCS Proprietary

Diffuser STARCS Proprietary

Vital booster and instrumentation rack STARCS Proprietary

Overview of the control and measurement system Zephyr Recording of fast response data Bandwidth: 30 kHz On-line monitoring IDA Recording of data Bandwidth:10 Hz On-line monitoring. Electronic Pressure Scanners (ESP) Recording of ”slow” pressures. (10 Hz) ABB 800 Control system for motor and valves FFA 1260 Signal conditioning Alarm System Compilation of data and presentation online of data, RMS, FFT etc. Alarm can invoke emergency stop FFA 1220 Strain gauges Temperatures Instationary Pressures Facility fixed transducers Stationary Pressures Data to customer Bearing temperature and vibration Emergency stop Motor control sensors MAESTRO Test sequence control STARCS Proprietary

Control Room STARCS Proprietary

Control System Display STARCS Proprietary

On-Line Compressor Performance Map STARCS Proprietary

Hulda low pressure compressor STARCS Proprietary

Vital LPC STARCS Proprietary

AIDA Aggressive Duct With Hulda Compressor STARCS Proprietary

Test compressor for max 5500 rpm Front view of Siemens Industrial Turbo-machinery test compressor with first stage guide vanes. (inlet hub not present) STARCS Proprietary

What is measured? Inlet and outlet pressures and temperatures Mass flow, rotational speed and drive shaft torque Vibration and loads on the rotor blades using strain gauges or tip-timing Vibration and loads on the stator vanes and the inlet guide vanes using strain gauges Stall detection using temperature sensors and unsteady pressure transducers Static pressures in the flow channel For monitoring: Rotor tip clearance, shaft position, temperature and vibration of the compressor bearings, lubrication oil pressure, temperature and mass flow Flow properties in the channel using traversing probes: pressure, temperature and flow angles

STARCS in-house designed and built Compressor Test Research Facility Summary STARCS in-house designed and built Compressor Test Research Facility Today a well proven concept Drive power and mass flow capabilities in parity with customer demands Unique capabilities with sub atmospheric outlet STARCS Proprietary